Process for preparation of methyl metharylate using recycled methanol

A process for production of methyl methacrylate comprising the process steps

• a) providing a feed composition comprising at least one C4 feed compound selected from isobutylene and tertiary butanol;
• b) providing methanol;
• c) subjecting the at least one C4 feed compound and the methanol to a first catalytic reaction zone to obtain a reaction phase comprising methyl tertiary butyl ether
• d) separating at least a first part of methanol from the reaction phase to obtain a first methanol phase and a reaction phase depleted in methanol;
• e) subjecting at least one of the reaction phase and the reaction phase depleted in methanol to a second catalytic reaction zone to obtain a splitting phase comprising isobutylene and methanol;
• f) optionally separating at least a first part of isobutylene from the splitting phase to obtain a first isobutylene phase and a splitting phase depleted in isobutylene;
• g) optionally subjecting at least one of the splitting phase and the first isobutylene phase to a first purification zone;
• h) subjecting at least one of the optionally purified splitting phase and the optionally purified first isobutylene phase to a third catalytic reaction zone to obtain an oxidation phase comprising at least one C4 oxidation product selected from methacrolein and methacrylic acid;
• i) optionally subjecting the oxidation phase to a second purification zone;
• j) subjecting the optionally purified oxidation phase to a fourth catalytic reaction zone to obtain an esterification phase comprising methyl methacrylate;
• k) optionally subjecting the esterification phase to a third purification zone.

An apparatus (1) for production of methacrylic acid, comprising

• i) at least one supply (2) for at least one C4 feed compound and at least one supply (3) for methanol, each supply being in fluid communication with
• ii) a first catalytic reaction zone (4) for at least partial conversion of the feed composition into MTBE;
• in fluid communication with
• iii) at least one first separation unit (5) for separation of methanol from the effluent of the first catalytic reaction zone (4);
• in fluid communication with
• iv) a mixing unit (6);
• in fluid communication with
• v) a second catalytic reaction zone (7) for at least partial splitting of MTBE;
• in fluid communication with
• vi) at least one second separation unit (8) for separation of a first isobutylene phase from the effluent of the second catalytic reaction zone (7);
• in fluid communication with
• vii) a third catalytic reaction zone (9) for at least partial oxidation of the first isobutylene phase to an oxidation phase comprising at least one C4 oxidation product selected from methacrolein and methacrylic acid.

An apparatus (1) for production of methyl methacrylate, comprising

• i) at least one supply (2) for at least one C4 feed compound and at least one supply (3) for methanol, each supply being in fluid communication with
• ii) a first catalytic reaction zone (4) for at least partial conversion of the feed composition into MTBE;
• in fluid communication with
• iii) at least one first separation unit (5) for separation of methanol from the effluent of the first catalytic reaction zone (4);
• in fluid communication with
• iv) a mixing unit (6);
• in fluid communication with
• v) a second catalytic reaction zone (7) for at least partial splitting of MTBE;
• in fluid communication with
• vi) at least one second separation unit (8) for separation of a first isobutylene phase from the effluent of the second catalytic reaction zone (7);
• in fluid communication with
• vii) a third catalytic reaction zone (9) for at least partial oxidation of the first isobutylene phase to an oxidation phase comprising at least one C4 oxidation product selected from methacrolein and methacrylic acid;
• in fluid communication with
• viii) a fourth catalytic reaction zone (10) for esterification of at least one component of the oxidation phase;
• in fluid communication with
• ix) a supply (11) for methanol, in fluid communication with the at least one first separation unit (5).